Fire retardant shaft wall

ABSTRACT

A wall construction adapted for enclosing an elevator shaft particularly suited for erection solely from one side thereof and resistant to normal distortions resulting from the heat of fire within the shaft.

United States Patent [191 Sauer et al.

FIRE RETARDANT SHAFT WALL Inventors: Gale E. Sauer, Williamsvil1e; Carl R.

Mapes, Kenmore, both of NY.

Assignee: National Gypsum Company, Buffalo,

Filed: Nov. ,12, 1971 Appl. No.: 198,483

Related Application Data Continuation of Ser. No. 34,656, May 5, 1970, abandoned.

US. Cl 52/479, 52/483, 52/495 Int. Cl E04b 2/30, E04b 2/78 Field of Search 52/479, 481, 483, 52/241, 495, 460, 282, 281, 729, 480, 770, 732, 730, 741, DIG. 5

References Cited UNITED STATES PATENTS 9/1944 Bronner 52/479 June 26, 1973 2,968,070 l/1961 Wolstead 52/479 X 3,189,139, 6/1965 Znamirowski et al. 3,363,377 1/1968 Beckman 52/720 X 3,418,776 12/1968 Manderbach et al 52/481 FOREIGN PATENTS OR APPLICATIONS 149,361 12/1952 Australia 52/481 Primary Examiner-Price C. Faw, Jr. Attorney-Robert F. l-lause [57] ABSTRACT A wall construction adapted for enclosing an elevator shaft particularly suited for erection solely from one side thereof and resistant to normal distortions resulting from the heat of fire within the shaft.

9 Claims, 5 Drawing Figures PATENTEflaunzsms 3.740.912

sum 1 n; 2

INVENTORS David Bieri Gale E. Souer Robert J. Pearson Carl R. Mopes I BY Jack A. Dowdy Fig.2 24

ATTORNEY PAIENTEDJUNZB 9n 3. 740.91 2

same or 2 NToRs 86 8o 84 50 David Bieri GGIG E. SGUer Carl R. Mopes Jack A. Dowd BY ZZL ATTORNEY FIRE RETARDANT SHAFT WALL This is a continuation of application Ser. No. 34,656, filed May 5, 1970, now abandoned.

This invention relates to an elevator shaft wall of gypsum boards affixed to vertically disposed lightweight metal studs, particularly studs having a central web having a width extending essentially in the direction of the thickness of the wall, a pair of oppositely directed flanges extending generally perpendicularly from the lateral edge of the web only on the shaft side of the wall and a plurality of spaced apart expansion relief slots in the web adjacent to the flanges.

The need for special construction systems for walls adapted for being assembled solely from one side, in constructing walls around elevator shafts, is completely obvious. At least in walls of gypsum board, the common construction systems involve assembling operations on both sides of the wall. Gypsum board walls are particularly desirable relative to providing fire retardance and relative to ease of handling of materials during construction.

Walls constructed of metal studs, particularly with one face of the metal stud exposed on a side of the wall where there is a potential of fires and high temperature, are subject to failure in a fire by high temperature expansion of the one side of the stud relative to the lack of expansion on the other side, and the resultant bowing of the wall into the fire-causing disruption and separation of the elements forming the wall.

It is an object of the present invention to provide an improved shaft wall, readily assembled from one side and relatively resistant to high temperatures on the opposite side.

It is a further object to provide a novel metal stud for supporting such improved shaft walls.

These and other objects will be clearly understood in considering the preferred embodiments as set forth in the specification and shown in the drawings in which:

FIG. 1 is an isometric view of a metal stud made in accordance with the present invention.

FIG. 2 is a cross sectional perspective view of a vertical wall embodying the stud of FIG. 1.

FIG. 3 is a view similar to cross section of FIG. 2, of a modified form of the invention.

FIG. 4 is a view similar to FIG. 3 of a further modified form of the invention.

FIG. 5 is a view similar to FIG. 3 of a still further modified form of the invention.

Referring to FIG. 1 there is shown an elongate, lightweight, metal stud 10, formed from sheet metal, preferably 24 gauge galvanized steel, and formed to include a central web 12, a pair of elongate, oppositely directed flanges l4 and 16 in a plane perpendicular to the general extent of web 12 and along one lateral edge thereof, and a single, elongate flange 18, parallel to flanges 14 and 16 and along the opposite lateral edge of web 12.

In the embodiment of FIG. 1, web 12 includes an elongate perpendicular portion 20, adjoining and perpendicular to flanges l4 and 16 and an elongate acutely angled portion 22 disposed between perpendicular portion and flange l8.

Flanges l4 and 16 are formed by the sheet metal of the stud being bent to extend from the web 12 outward to the edge 24 of one flange 14, being reversely folded to extend therefrom to the outer edge 26 of flange 16,

and then being reversely bent back on itself for a short distance from edge 26.

A short lip 28 extends inwardly, perpendicularly, from the edge of single flange 18 remote from web 12, for stiffening of flange 18.

A plurality of openings 30, 30 are disposed in web 12, at about 6 inch intervals, having an extent of about three inches along the side 32 of the opening 30 which is adjacent the flanges 14 and 16. Openings 30, 30 are shown in the preferable form of isosceles triangles, however they can be merely slits extending along the junction of web 12 and flanges l4 and 16 or any shape opening extending up to about halfway across the width of web 12.

In FIG. 2, the stud 10 is shown supporting wall 40, which is constructed on floor 42 at an edge 44 adjacent an elevator shaft 46. Studs 10 are vertically disposed at two foot spacings with the bottom of each stud 10 affixed within a floor channel 48 affixed to floor 42.

One inch thick, 2 foot wide gypsum core boards 50 are disposed between adjacent studs 10 with a back face 52 abutting the inner surface 52 of flanges l4 and 16. Core boards 50 are a standard form of gypsum board, with a set gypsum core enclosed within a paper covering. Boards 50 extend the full distance from the floor 42 to the ceiling thereabove (not shown). Selfdrilling, self-tapping drywall screws 54 affix the boards 50 to the flanges l4 and 16.

Two layers of 4 foot wide inch fire-rated gypsum wallboard 56 is attached to the outer surface 57 of flange 18 with appropriate length drywall screws 54, with the lateral edges 58 of the boards 56 of the two respective layers being located over alternate studs 10.

In the modification of FIG. 3, the stud 10 is provided with a plurality of small holes 60 located in web 12 along a line 1 inch from the flanges 14 and 16, and core board 50 is affixed against flanges l4 and 16 by small nails or clips 62 inserted in the holes 60. The alternative of a single layer of fire-rated wallboard 56 is shown screw-attached to flange 18.

In FIG. 4, the stud 10 has a prelaminated panel mounted on each of the respective flanges 14 and 16, with the respective flanges disposed in between the laminations 72, 72, along each of the panel vertical edges 74.

FIG. 5 shows a modified stud having a flat web 82, flanges 84 and 86 along edge of web 82 and a single flange 88 along the other edge of web 82. Core boards 50 are affixed against flanges 84 and 86 with nails or clips 62. Two layers of fire-rated gypsum wallboard 56 are screw-attached to flange 88.

The erection of the walls of the present invention can be done by builders working from only the one side of the wall. After one stud 10 or 80 is affixed at its bottom and top, a core board 50 or panel 70 is positioned relative thereto, working from the one side of the wall, and another stud is then positioned relative to the opposite edge of the board or panel. Subsequently, the wallboards 36 are screw-attached to the studs 10 or 80. Accordingly, a first series of coplanar gypsum boards 50 or panels 70 are disposed against and are supported by the inner surface 53 of flanges l4 and 16, or of flanges 84 and 86. A second series of coplanar gypsum boards 56 are disposed against and are supported by the outer surface 57 of flange 18 or 88.

The studs may alternatively be all affixed in place first, particularly the flatwebbed stud 80, after which boards 50 are respectively set in place and affixed against flanges l4, 16 or 84, 86.

The stud permits of improved access for the purpose of screw-attaching core boards 50 to flanges 14 and 16, by reason of the angled portion 22 of web 12. The affixation of core boards 50 with nails or clips 62 is preferred, relative to screw attachment, with studs 80, which lack a web angled portion.

The presence of openings 30, 30 in either the stud 10 or the stud 80 is for the purpose of expansion relief of the side of the stud facing an elevator shaft, in the event of fire and high temperatures in the elevator shaft. It has been found that wall structures of the type disclosed herein, without such means for expansion relief in the studs, undergo an extreme bowing into the zone of the shaft under high temperature conditions in the shaft. Openings 30 permit the flanges 14, 16 to bow toward the shaft in a plurality of short sections adjacent each opening 30, whereby the balance of the stud remains substantially in place, and the wall continues to restrict the passage of tire and heat.

Having completed a detailed disclosure of the preferred embodiments of our invention so that those skilled in the art may practice the same, we contemplate that variations may be made without departing from the essence of the invention.

We claim:

1. A wall, readily assembleable from one side and suitable for construction where the second side is relatively inaccessible, comprising a plurality of spaced apart vertically disposed elongate, formed sheet metal studs, each said stud being formed from a single sheet of sheet metal, gypsum boards on the said one side of said wall screw attached to the outer surface of a single solitary flat screwable portion of each of said studs, said flat screwable portion of each said stud facing said one side of said wall, and gypsum boards on said second side of said wall affixed against the inner surface of a pair of oppositely directed flanges, said oppositely directed flanges being formed from an elongate portion of said sheet metal which extends in width from the outer edge of one of said flanges to the outer edge of the opposite said flange, said oppositely directed flanges forming the second side of said stud on the said second side of said wall, and portions of single thickness of said sheet metal stud adjoining said flat screwable portion on said one side and said oppositely directed flanges on said second side.

2. A wall comprising a plurality of spaced-apart, vertically disposed, elongate, formed sheet metal studs and a plurality of gypsum boards affixed to said studs, said boards and said studs forming a wall which is suitable for erection from a first side without need for anyone on the opposite side, said studs each being formed from a single sheet of sheet metal and having a web formed from a single thickness of said sheet metal disposed substantially perpendicular to the plane of the wall, said studs each having a single solitary flange extending parallel to the plane of the wall from the edge of said web forming one side of said stud on said wall first side, said studs each having a pair of oppositely directed elongate flanges disposed in a plane parallel to the plane of the wall, said pair of flanges forming the opposite side of said stud, means joining said three flanges to said web, a first series of coplanar gypsum boards having lateral edge portions disposed against, and supported by the inner surface of said oppositely directed flanges of said studs, means for holding said lateral edge portions against said oppositely directed flanges and a second series of coplanar gypsum boards disposed against and supported by the outer surface of said single flanges of said studs.

3. The wall of claim 2 wherein said web includes a substantially flat portion which extends between a pair of lateral edges of coplanar gypsum boards of said first series, said flat portion being substantially perpendicular to the plane of the wall and having a width substantially greater than the thickness of said gypsum boards of said first series, said stud being formed to permit insertion and removal of one of said pair of lateral edges of one gypsum board while said opposite lateral edge of said one gypsum board is disposed against one of the pair of flanges of an adjacent stud.

4. A wall construction as defined in claim 2 wherein the side of said wall with said first series of coplanar gypsum boards is adjacent an elevator shaft.

5. A wall construction as defined in claim 2 wherein said studs are formed from a single elongate sheet of steel of about 24 gauge and said pair of oppositely directed flanges being formed from an elongate portion of said sheet metal which extends in width from the outer edge of one of said flanges to the outer edge of the opposite said flange.

6. A wall construction as defined in claim 2 wherein said web is all in a single plane perpendicular to the planes of said flanges.

7. A wall construction as defined in claim 2 wherein said web comprises two portions, one portion being adjacent and perpendicular to said oppositely directed flange and the other portion being adjacent and acutely angled to said single flange.

8. The wall construction of claim 2 wherein said studs are disposed at about two foot spacings and said first series of coplanar gypsum boards are about two feet by one inch by room height.

9. The wall construction of claim 2 wherein said studs are disposed at about two foot spacings and said first series of coplanar gypsum boards consist of two laminated boards of about two feet by half inch by room height.

Po-ww UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 740,911 Dated June 26 1973 Inventor) Gale E. Sauer and Carl R. Mapes It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column -2, line 22, "52" (second occurrence)should be 53---; same column, line 59, "36" should be "-56-".

Inventors names on drawing 'David Bieri, Gale E.

Sauer, Robert J. Pearson, Carl R. Mapes and Jack A. Dawdy" should be --Gale 'E. Sauer and Carl R. Mapes---.

Signed and Isealed this 19th day of February 1974.

(SEAL) Attest:

EDWARD M.FLETCHER,JR. C. MARSHALL DANN Att ti Offi Commissioner of Patents 

1. A wall, readily assembleable from one side and suitable for construction where the second side is relatively inaccessible, comprising a plurality of spaced apart vertically disposed elongate, formed sheet metal studs, each said stud being formed from a single sheet of sheet metal, gypsum boards on the said one side of said wall screw attached to the outer surface of a single solitary flat screwable portion of each of said studs, said flat screwable portion of each said stud facing said one side of said wall, and gypsum boards on said second side of said wall affixed against the inner surface of a pair of oppositely directed flanges, said oppositely directed flanges being formed from an elongate portion of said sheet metal which extends in width from the outer edge of one of said flanges to the outer edge of the opposite said flange, said oppositely directed flanges forming the second side of said stud on the said second side of said wall, and portions of single thickness of said sheet metal stud adjoining said flat screwable portion on said one side and said oppositely directed flanges on said second side.
 2. A wall comprising a plurality of spaced-apart, vertically disposed, elongate, formed sheet metal studs and a plurality of gypsum boards affixed to said studs, said boards and said studs forming a wall which is suitable for erection from a first side without need for anyone on the opposite side, said studs each being formed from a single sheet of sheet metal and having a web formed from a single thickness of said sheet metal disposed substantially perpendicular to the plane of the wall, said studs each having a single solitary flange extending parallel to the plane of the wall from the edge of said web forming one side of said stud on said wall first side, said studs each having a pair of oppositely directed elongate flanges disposed in a plane parallel to the plane of the wall, said pair of flanges forming the opposite side of said stud, means joining said three flanges to said web, a first series of coplanar gypsum boards having lateral edge portions disposed against, and supported by the inner surface of said oppositely directed flanges of said studs, means for holding said lateral edge portions against said oppositely directed flanges and a second series of coplanar gypsum boards disposed against and supported by the outer surface of said single flanges of said studs.
 3. The wall of claim 2 wherein said web includes a substantially flat portion which extends between a pair of lateral edges of coplanar gypsum boards of said first series, said flat portion being substantially perpendicular to the plane of the wall and having a width substantially greater than the thickness of said gypsum boards of said first series, said stud being formed to permit insertion and removal of one of said pair of lateral edges of one gypsum board while said opposite lateral edge of said one gypsum board is disposed against one of the pair of flanges of an adjacent stud.
 4. A wall cOnstruction as defined in claim 2 wherein the side of said wall with said first series of coplanar gypsum boards is adjacent an elevator shaft.
 5. A wall construction as defined in claim 2 wherein said studs are formed from a single elongate sheet of steel of about 24 gauge and said pair of oppositely directed flanges being formed from an elongate portion of said sheet metal which extends in width from the outer edge of one of said flanges to the outer edge of the opposite said flange.
 6. A wall construction as defined in claim 2 wherein said web is all in a single plane perpendicular to the planes of said flanges.
 7. A wall construction as defined in claim 2 wherein said web comprises two portions, one portion being adjacent and perpendicular to said oppositely directed flange and the other portion being adjacent and acutely angled to said single flange.
 8. The wall construction of claim 2 wherein said studs are disposed at about two foot spacings and said first series of coplanar gypsum boards are about two feet by one inch by room height.
 9. The wall construction of claim 2 wherein said studs are disposed at about two foot spacings and said first series of coplanar gypsum boards consist of two laminated boards of about two feet by half inch by room height. 